Process for sugar modulation

ABSTRACT

The present invention relates to a method for producing a food product comprising hydrolysed starch, as well as to products obtainable by the method. The method has the advantage of reducing the amount of sugar (i.e. maltose) produced by hydrolysis as compared to conventional methods of starch hydrolysis and present the additional advantage of providing good processability for the food product.

CROSS REFERENCE TO RELATED APPLICATIONS

The present application is a National Stage of International ApplicationNo. PCT/IB2018/059749, filed on Dec. 7, 2018, which claims priority toEuropean Patent Application No. 17207572.3, filed on Dec. 15, 2017, theentire contents of which are being incorporated herein by reference

TECHNICAL FIELD OF THE INVENTION

The present invention relates to a method of preparing a food productcomprising hydrolysed starch. In particular, the present inventionrelates to a method of preparing a food product comprising hydrolysedstarch with lower amounts of maltose, as compared to conventionalhydrolysis processes. The method of present invention also present thebenefit of providing good processability for the food product.

BACKGROUND OF THE INVENTION

In current manufacturing processes for production of starch-containingfood products, amylolytic enzymes are used to break down starch anddecrease product viscosity. High viscosity products are difficult tohandle in the manufacturing line, and therefore the starch is treatedwith enzymes which results in lower viscosity. However, starchdegradation also leads to the production of disaccharides, in particularmaltose among others. There is a growing concern of the effects of sugar(mono- and disaccharide) levels in food products, and therefore lowerlevels of sugars such as maltose, are desired. Sugar levels are aparticularly important concern in the production of food products forinfants and/or children.

It is known that cereal flour contains also natural enzymes whichproduce maltose under specific conditions. Gelatinization and theactivity of this enzyme seem to play an important role on extent ofmaltose production (Effect of Gelatinization and Hydrolysis Conditionson the Selectivity of Starch Hydrolysis with alpha-Amylase from Bacilluslicheniformis. T. Baks et al., J. Agric. Food Chem. 2008, 56, 488-495;Etude de la mesure de l'activité de la bêta et de l'alpha-amylase desfarines de froment. R. Geoffroy, Novembre-Décembre 1954).

Hence, an improved process for hydrolysis of starch would beadvantageous.

SUMMARY OF THE INVENTION

Thus, an object of the present invention relates to providing a methodfor producing a food product comprising hydrolysed starch.

In particular, it is an object of the present invention to provide amethod that solves the above mentioned problems of the prior artconcerned with levels of sugar in foods comprising hydrolysed starch.More in particular, it is an object of the present invention to providea method that provides food product comprising hydrolysed starch withlower amounts of maltose, as compared to conventional hydrolysisprocesses.

It is also an object of the present invention to provide a method toprepare food product comprising hydrolysed starch with lower amounts ofmaltose, as compared to conventional hydrolysis processes and whichmethod still results in good processability of the food product duringits preparation.

Thus, one aspect of the invention relates to a method for producing afood product comprising hydrolysed starch, said method comprising thesteps of:

-   -   a) Providing a starting material which comprises both starch and        at least one amylolytic enzyme,    -   b) Providing as ingredients: water, optionally at least one        further amylolytic enzyme and optionally one or more other        ingredients,    -   c) Mixing the starting material of step a) and the ingredients        of step b)    -   d) adjusting the temperature of the mixture of step c) to a        temperature lower than 55 degrees C., and    -   e) simultaneously to step d) subjecting said mixture of step c)        to high shear mixing,    -   f) Incubating the mixture of step e) such that the desired        degree of hydrolysis is achieved, thereby obtaining a food        product comprising hydrolysed starch.

A further aspect of the invention relates to a food product obtainableor obtained by the methods of the invention.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 is a simplified process diagram for the in-line hydrolysis set-upshowing equipment according to the process of the invention (Ring Layermixer—hereby shortened RLM) or conventional equipment (for example aline set up comprising an hydrolysis tank (ZL) equipped with a DirectSteam injector—hereby shortened—DSI).

FIG. 2 is a graph reporting results obtained with experiments describedin Example 6 (maltose generation with ring layer mixer under differenttemperature conditions)

The present invention will now be described in more detail in thefollowing.

DETAILED DESCRIPTION OF THE INVENTION Definitions

Prior to discussing the present invention in further details, thefollowing terms and conventions will first be defined:

The term ‘degrees C.’ or ‘deg C.’ refers to degrees Celsius.

Numerical ranges as used herein are intended to include every number andsubset of numbers contained within that range, whether specificallydisclosed or not. Further, these numerical ranges should be construed asproviding support for a claim directed to any number or subset ofnumbers in that range. For example, a disclosure of from 1 to 10 shouldbe construed as supporting a range of from 1 to 10 (including 1 and 10),from 2 to 8, from 3 to 7, from 1 to 9, from 3.6 to 4.6, from 3.5 to 9.9,and so forth. All references to singular characteristics or limitationsof the present invention shall include the corresponding pluralcharacteristic or limitation, and vice versa, unless otherwise specifiedor clearly implied to the contrary by the context in which thereference, is made.

Within the context of the present invention, the expression “at atemperature ranging from X to Y” has to be intended to indicate anytemperature which is comprised between the temperatures X and Y, suchtemperatures X and Y also being also included in the range, unlessspecifically indicated.

The term “and/or” used in the context of the “X and/or Y” should beinterpreted as “X”, or “Y”, or “X and Y”.

Unless defined otherwise, all technical and scientific terms used hereinhave the same meaning as commonly understood by one of ordinary skilledin the art.

The term “starch” as used herein refers to the polysaccharidemacromolecules used for energy storage by most plants. It consists of alarge number of glucose units joined by glycosidic bonds. The twohigh-molecular weight components of starch are amylose and amylopectin.Starch is found for example in cereals, tubers and legumes. Examples oftubers include potatoes, sweet potatoes, cassava, yams etc. Examples oflegumes include beans (such as pinto, red, navy), peas, lentils,chickpeas, peanuts etc. When the term “starch” is used in the context ofthe present invention, it may indicate starch from one plant origin or amixture of starches from different plant origins.

The term “cereal” as used herein refers any grass cultivated for theedible components of its grain. Examples of cereal are wheat, rice,maize, barley, rye, oats, buckwheat, millet, quinoa, sorghum et cetera.

The term “food product” as used herein refers to a finished productsuitable for human consumption and/or to a intermediate preparationwhich is meant to deliver a finished product after being subject toadditional processing step(s), comprising a heat treatment. Specificnon-limiting examples of finished food products are biscuits, wafers,cereals (breakfast and infant), bread, bakery products, pizza, cerealmilk drink, baby food and the like. Specific non-limiting examples ofpreparation which are meant to deliver a finished product after beingsubject to additional processing steps are batters, doughs, slurries andthe like.

Within the context of the present invention, “Infant cereal” productsidentifies two main categories: complete cereal product which need to bereconstituted in water as they already contain all the necessarynutrients to be delivered with the meal; and standard cereal productwhich are meant to be reconstituted with milk, infant formula, follow-onformula and/or GUMs.

Within the context of the present invention, the term “all familycereals” identifies compositions containing cereals to be consumed bychildren and adults. For example, all family cereals are reconstitutedin milk (whole or skimmed) and consumed in the format of a porridge.

The term “gelatinization” as used herein refers to the process ofswelling and opening of starch granules, where the intermolecular bondsof starch molecules in a starch granule are broken, leading to thebinding of water and the irreversible dissolving of the starch granulein water. The determination of the gelatinization temperature is wellknown to the skilled person, and may be performed by e.g. the Kofler hotstage microscopy (see further Table 1 and notes), or for example byDifferential Scanning calorimetry (DSC).

The gelatinizing temperature refers to the temperature (or temperaturerange) at which a starch gelatinizes. Different species of plants yieldstarches which may have different gelatinization temperatures, and theseare well-known in the art. Gelatinization temperature ranges for somestarches, are given below in Table 1 by way of example.

TABLE 1 Typical gelatinization temperatures for some starchesGelatinization Starch type temperature range (° C.)* Wheat 58-61-64 Rice68-74-78 Maize (Corn) 62-67-72 Potato 58-63-68 Tapioca 59-64-69 Waxymaize 63-68-72 Sorghum 68-74-78 *Determined by Kofler hot stagemicroscopy (onset- midpoint-end) (Table 8.1 “Starch: Chemistry andTechnology”, edited by James BeMiller and Roy Whistler, Food Science andTechnology International Series, Third edition 2009).

The term “amylolytic enzymes” as used herein refers to any enzymecapable of converting starch into dextrins and sugar (mono- ordisaccharides). Examples of amylolytic enzymes include amylases andpullulanase. Examples of amylases include alpha-amylases, beta-amylases,gamma-amylases.

Method of the Invention

In conventional processes for preparing starch-containing foods, theviscosity of the starch presents a problem. In order to avoid viscositybuild-up, enzymatic hydrolysis of the starch is often performed.However, such hydrolysis may lead; among others, to the production ofmaltose, increasing the level of sugar present in the product of theprocess. The amount of sugars present in food is the subject of someconcern, and therefore it is desirable to limit the amount of simplesugars (mono- and disaccharides) present in food products. The presentinvention is based on the surprising finding that implementation of themethod of the invention yields a food product comprising hydrolysedstarch with lower amounts of maltose, as compared to conventionalhydrolysis processes.

Maltose generation is believed to be the result of the action of twotypes of enzymes, working synergistically: (1) the wheat flourendogenous β-amylases; directly forming maltose; (2) the added BAN(α-amylase); forming dextrins (for the β-amylases to act on) and maltosein lower amounts.

In the studies conducted by the inventors, maltose generation proved tobe dependent on temperature. Without wishing to be bound by theory, itis believed that each temperature leads to a different combination ofenzyme activity levels (as the enzyme are temperature sensitive), thusdetermining different balance between activities (1) and (2) abovementioned and consequently different extents of maltose generation.

In the studies conducted by the inventors it was also surprisingly foundthat maltose generation proved to be dependent on the mixing conditionsimplemented for step e). In particular, it resulted that under highshear mixing conditions the maltose formation may be further reduced ata temperature lower than 55 deg C. Without wishing to be bound bytheory, it is believed that, under high shear, mixing results to be moreefficient and the associated temperature distribution within theequipment results to be more homogeneous (narrower temperature curvedistribution). The lower maltose levels obtained with high shear mixer(in particular with a ring layer mixer) at a temperature below 55 deg C.might thus be explained by the narrower temperature distribution withinthe equipment and the resulting narrower fraction of slurry exposed tothe temperature 65° C., where maltose seems to be preferentially formed(as shown by the results of Example 4).

In particular, the inventors surprisingly found that with the method ofthe present invention which operates below 55° C. under high shearmixing, little maltose is formed. Without wishing to be bound by theory,it is believed that this effect is due to the low activity of exogenousalpha-amylase in this temperature range and hence reduced level ofsubstrates for β-amylases, despite the β-amylase being very active.

The inventors also surprisingly found that with the method of thepresent invention good processability of the slurry which undergoesroller drying process can be obtained. As shown in Example 7 of thepresent invention the behaviour of the sump obtained according to themethod of the present invention was surprisingly bubbly.

“Bubbly” sump in a bi-cylinder roller-dryer is a key processingcondition for a good film formation in subsequent roller drying. Thebubbling in the sump allows to mix the slurry inside the sump, andprevents the surface from drying up. If the sump does not bubble, thenincreasing the water content in the slurry is usually required to avoiddrying of the surface and issues with roller-drying with a consequentdrop of total solids. A drop of total solids is not desired as it leadsto output decrease.

The method of the invention thus relates in one embodiment to a methodfor producing a food product comprising hydrolysed starch, said methodcomprising the steps of:

-   -   a) Providing a starting material which comprises both starch and        at least one amylolytic enzyme,    -   b) Providing as ingredients: water, optionally at least one        further amylolytic enzyme and optionally one or more other        ingredients,    -   c) Mixing the starting material of step a) and the ingredients        of step b) d) adjusting the temperature of the mixture of        step c) to a temperature lower than 55 deg C., and    -   e) simultaneously to step d) Subjecting said mixture of step c)        to high shear mixing,    -   f) Incubating the mixture of step e) such that the desired        degree of hydrolysis is achieved, thereby obtaining a food        product with hydrolysed starch.

Starting Material

The method of the invention involves providing a starting material whichcomprises both starch and at least one amylolytic enzyme.

Some embodiments relate to methods according to the invention whereinthe starting material is a plant preparation, such as a preparation ofthat part of the plant which contains the majority of the plant's starchstorage granules. In some embodiments such preparations may also includeother parts of the plant, such as stems, leaves etc. Such plantpreparations typically also comprise at least one amylolytic enzyme.

In particular embodiments, the starting material is a dry plantpreparation, such as a flour. Thus, the starting material may beselected from a flour of one or more grains, such as a flour selectedfrom wheat flour, rice flour, maize flour, barley flour, rye flour, oatflour, buckwheat flour, millet flour, quinoa flour, sorghum flour; aflour made from one or more tubers, such as potato, cassava; a flourmade from legumes such as pea flour; or combinations thereof.

In one embodiment, the starting material comprises at least a portion ofwheat flour.

The term dry as used herein means comprising water in the range from0.01 to 20% w/w such as from 0.01 to 16% w/w, 0.01 to 15% w/w, 0.01 to12% w/w, 0.01 to 8% w/w, 0.01 to 5% w/w, 0.01 to 3% w/w, w/w such as0.01 to 0.5% w/w %, or for example being essentially free from water.For example, wheat flour may contain up to 15% moisture (w/w), such asfrom 12 to 15% w/w, 12 to 14% w/w or 12 to 13% w/w, and is considered adry plant preparation.

The term flour as used herein refers to the product of milling. Theparticle size or particle size distribution of the flour is notconsidered to be critical for the method. Plant preparations in the formof flours which are suitable as starting material for production ofhydrolysed starch are known in the art, and selection of such is alsowithin the skill of the person skilled in the art.

Endogenous Amylolytic Enzymes

The starting material for the method of the invention comprises bothstarch and at least one amylolytic enzymes. The at least one amylolyticenzymes present in the starting material may be endogenous amylolyticenzymes. In other words, the starting material may comprise amylolyticenzymes which have not been added by human intervention, but rather havebeen co-extracted together with the starch (granules) from the plantmaterial, i.e. endogenous amylolytic enzymes. Examples of endogenousamylolytic enzymes include alpha-amylases, and beta-amylases and gammaamylases. In one embodiment, endogenous amylolytic enzymes arebeta-amylases.

The invention in one embodiment relates to a method according to theinvention wherein in step d) is the temperature of the mixture of stepc) is adjusted to a temperature lower than 55 deg C. Such temperatureadjustment is simultaneous to subjecting the mixture of step c) to highshear mixing as described in step e).

The endogenous amylolytic enzymes digest starch molecules and yieldmaltose. In one embodiment, one advantage of the method according to theinvention is that, at a temperature lower than 55 deg C., the activityof added amylolytic enzymes decreases very rapidly thereby preventingthe production of dextrins and thereby reducing the amount of maltose inthe final food product.

Providing Water

The method of the invention comprises providing water and mixing withthe starting material. Enzymatic hydrolysis of starch requires thepresence of water. If the starting material is provided in dry form,such as for example a dry plant preparation, such as for example a plantflour, water may be provided by one or more of steam injection, additionof water, the provision of an aqueous further ingredient, provision ofan aqueous solution of at least one further amylolytic enzyme orcombinations thereof.

If the starting material is not in dry form, but comprises more than 20%water w/w, or for example more than 15% water w/w, the water may beconsidered to be at least partially provided by the starting material.In some embodiments, further water may also be provided, for example byone or more of steam injection, addition of water, the provision of anaqueous further ingredient, provision of an aqueous solution of at leastone further amylolytic enzyme or combinations thereof.

In particular embodiments, the provision of water comprises providingwater in the form of steam. In particular embodiments, water in the formof steam is provided by way of steam injection, such as direct steaminjection. In other embodiments, water in the form of steam is providedby way of steam infusion (where ingredients are sprayed in a steamatmosphere). Direct steam injection has the advantage of rapidly heatingthe mixture of starting material, the optionally water provided fromabove-mentioned other sources, the at least one further amylolyticenzyme and any optional further ingredients, at the same time as wateris added.

Direct steam injection may be achieved by any suitable means, and theselection of such a means is within the skill of a person of ordinaryskill in the art.

In one embodiment, when the provision of water is at least partially inthe form of steam, such steam provision may occur simultaneously tosteps d) and e).

Some embodiments relate to the method according to invention, whereinsaid mixture (step c) has a total solids content in the range of 20 to60% w/w, such as 30 to 60% w/w, such as 35 to 60% w/w, such as such as40 to 60% w/w, such as 45 to 60%, such as 50 to 60% w/w, such as 55 to60%; or for example from 20 to 55% w/w, 20 to 50% w/w, 20 to 40% w/w; orfor example 30 to 50% w/w, or 30 to 40% w/w.

Further Amylolytic Enzymes

The method of the invention comprises a step wherein optionally at leastone further amylolytic enzyme is added to the starting material andmixed together with the starting material. Thus, in step b) anamylolytic enzyme may be provided, which is in addition to theamylolytic provided in step a), and all ingredients mixed in step c).

In some embodiments, the at least one further amylolytic enzyme isprovided in addition to an endogenous amylolytic enzyme provided in stepa).

The at least one further amylolytic enzyme may be any suitableamylolytic enzyme, for example an amylase (such as alpha-amylase and/orbeta-amylase) and/or pullalanase. In particular embodiments, the atleast one further amylolytic enzyme is one or more of an alpha amylaseand a beta amylase. In particular embodiments, the at least one furtheramylolytic enzyme is one alpha amylase The invention in some embodimentsrelates to a method according to the invention wherein said at least onefurther amylolytic enzyme comprises or consists of amylase, for examplealpha-amylase not endogenous to the provided starting material.

As mentioned above, the at least one further amylolytic enzyme may beprovided as an aqueous solution.

Amylolytic enzymes are commercially available from several distributors,for example from DuPont, Novozymes, DSM, BioCatalysts.

Further Ingredients

In some embodiments of the invention, one or more other ingredients areincluded. The one or more further ingredients may be any ingredientsuitable for a food. In particular embodiments, the one or more otheringredients added in step b) are not negatively affected by thetemperature and high shear mixing of step d) and e). Examples of one ormore other ingredients may be fats such as oils, protein or amino acidsources, carbohydrate sources such as sugars and/or pre-biotics,minerals, vitamins and the like.

In one embodiment, no other ingredients are provided in step b). Theproduct obtained by this method would be an intermediate, not finished,food product referred to herein as a hydrolysed carbohydrate ingredient(HCI). See further below “Product obtainable by the method”.

In some embodiments of the method, the food product obtained by a methodof the invention is itself a finished food product. In such embodiments,at least one other ingredient is provided in step b), such as one ormore ingredients such as for example fats such as oils, protein or aminoacid sources, carbohydrate sources such as natural or refined sugarsand/or pre-biotics, minerals, fruit ingredients, milk based ingredientsand vitamins. In one embodiment, fats such as oils are provided in stepb).

Mixing and Premixing

The method of the invention comprises a step of mixing the startingmaterial of step a) and the ingredients of step b).

It is not believed that this mixing is critical, and thus may be done inany suitable manner. The selection of a method of mixing is within theskill of a person skilled in the art.

In some embodiments of the method according to the invention, the stepc) of mixing the starting material of step a) and the ingredients ofstep b), is performed prior to the step d). This means that the startingmaterial and ingredients are mixed prior to the adjustment oftemperature which takes place in step d). This is referred to as“pre-mixing”.

However, premixing of ingredients is not necessary: dry ingredients andwater can be directly fed inside the high shear mixer, such as a RingLayer Mixer.

In other, particular embodiments, the step c) of mixing takes placesimultaneously with step d). For example, the starting material of stepa) and the ingredients of step b) may be fed to a container, in whichheating is performed and in which, at the same time, mixing takes place.In one embodiment, steps c), d) and e) are performed in a ring layermixer, simultaneously.

Adjusting Temperature in Step d)

The method of the invention comprises a step d) where the temperature ofthe mixture obtained in step c) is adjusted to a temperature below 55deg C., for example at a temperature equal or lower than 50 deg C., forexample at a temperature ranging from 20 to 50 deg C., from 30 to 50 degC., for example at a temperature ranging from 35 to 45 deg C. Thetemperature is adjusted simultaneously with the high shear mixing of themixture.

In some embodiments, the extent of gelatinization of the starch is below30% w/w, for example below 20% w/w, for example below 15% w/w.

In particular embodiments, the step d) (adjusting the temperature of themixture from step c) to a temperature below 55 deg C., for example at atemperature equal or lower than 50 deg C., for example at a temperatureranging from 20 to 50 deg C., from 30 to 50 deg C., for example at atemperature ranging from 35 to 45 deg C. is performed by direct steaminjection.

High Shear Mixing

The method of the invention comprises a step of subjecting the mixtureof step c) to high shear mixing, for example by use of a high shearmixer.

The high shear mixing may be for a time period of 0.5 seconds to 10minutes, such as 1 second to 10 minutes, such as from 1 second to 5minutes, such as 1 second to 3 minutes, such as 1 second to 120 seconds,such as 1 second to 90 seconds, such as 1 second to 60 seconds.

The high shear mixing may be such that the mixture is homogenized withina time period of 1 second to 10 minutes, such as from 1 second to 5minutes, such as 1 second to 3 minutes, such as 1 second to 120 seconds,such as 1 second to 90 seconds, such as 1 second to 60 seconds.

In particular embodiments, the high shear mixing is such that themixture is homogenized within a time period of 1 second to 50 seconds,such as 1 second to 40 seconds, 1 second to 30 seconds.

In this context, homogenized means where the starch granules are swollenand dispersed, preferably uniformly, into the media.

Said high shear mixing is performed simultaneously with the adjusting ofthe temperature discussed above. As discussed, it is believed that thesimultaneous temperature adjustment and high shear mixing work togetherto give hydrolysis of the starch, while minimizing the production ofmono- and disaccharides, especially maltose.

Shear forces are unaligned forces pushing one part of the body in onedirection, and another part of the body in the opposite direction.

In some embodiments, the invention relates to methods of the inventionwherein said high shear mixing in step e) may be achieved by using ahigh shear mixer. High shear mixers disperse an ingredient or ingredientmix into a main continuous phase, for example a solid, semi-liquid orliquid phase. Typically, a mobile rotor or impeller is used togetherwith a stationary component known as a stator together to create highshear. Thus, a high shear mixer may be defined as a mixer comprising arotor and at least one stator. Examples of high shear mixers are wellknown in the art, and include for example ring layer mixers.

Non-limiting examples of high shear mixers according to the presentinvention are: ring layer mixer, homogenizer, paddle mixer, pin mixer,pelletizer, granulator and high shear pump.

In one embodiment of the present invention, the high shear mixing instep e) is not an extruder. In one embodiment, the high shear mixeraccording to the present invention is not an extruder.

The term high shear mixing as used herein may be defined as the mixingwhich achieves such shear as may be achieved by using a Ring LayerMixer, for example under the conditions described in the Examples.

Ring Layer Mixer

Any apparatus which can achieve high shear mixing as well as allow forsimultaneous temperature adjustment may be used.

Particular embodiments of the invention relate to methods according tothe invention wherein the high shear mixing step e) is achieved by useof a high shear mixer, in particular a ring layer mixer.

A ring layer mixer delivers high peripheral speeds. The resultingcentrifugal force brings the product outwards into a ring layer on thevessel side wall. The high speed difference between the rotatingagitator and the mixing drum, combined with the use of different mixingelements ensures a high shear mixing.

Direct steam injection is simple to implement when using a ring layermixer, which is a further advantage of using a ring layer mixer. This isdue to the fact that injection may be carried out at atmosphericpressure.

Some embodiments relate to the method according to the invention,wherein steps c) to e) are performed in a Ring Layer Mixer. Otherembodiments relate to where steps c) up to and including at least a partof step f) are performed in a Ring Layer Mixer

Particular embodiments relate to methods of the invention wherein thesteps a) to e) are performed in a Ring Layer Mixer. As mentioned below,other embodiments relate to methods of the invention wherein steps a toc) are performed prior to use of the ring layer mixer (i.e., pre-mixingstep) and steps d) to e) are performed in the ring layer mixer.

Other particular embodiments relate to the method of the invention wheredirect steam injection is used to adjust the temperature in step d) andring layer mixer is used for high shear mixing of step e).

In one embodiment of the present invention, the speed of the ring layermixer may range from 500 to 2500 rpm.

Incubating

The method according to the invention comprises the step f) ofincubating the mixture obtained by high shear mixing from step e) suchthat the desired degree of hydrolysis is achieved.

This incubation step relates to a step when the mixture from step e) iskept at a certain temperature, for a certain period of time. Thisincubation allows the enzymes, to act in order to hydrolyse the starch.In some embodiments, mixing may take place in the incubation period. Themixing avoids sedimentation, and/or facilitates an even and stabletemperature profile. In particular embodiments, the mixing in step f) isnot high shear mixing.

In some embodiments, the incubation of step f) is performed at atemperature in below 55 deg C., for example at a temperature equal orlower than 50 deg C., for example at a temperature ranging from 30 to 50deg C., for example at a temperature ranging from 35 to 45 deg C.; for aperiod of time in the range from 1 minute to 24 hours, such as 1 minuteto 12 hours, such as from 1 minute to 10 hours, such as from 1 minute to8 hours, such as 1 minute to 7 hours, such as 1 minute to 6 hours, suchas 1 minute to 5 hours, such as 1 minute to 4.5 hrs, such as 1 minute to4 hours, such as 1 minute to 3.5 hours, such as 1 minute to 3 hours,such as 1 minute to 2.5 hours, such as 1 minute to 120 minutes, such asfrom 2 minutes to 80 minutes, such as from 10 minutes to 80 minutes, 10to 60 minutes; or for example from 1 minute to 10 minutes, 1 to 8minutes, or 1 to 5 minutes, or for example from 2 minutes to 10 minutes.

In-Line Dosing

In some embodiment of the present invention, the intermediate semifinished ingredient obtainable according to method of the presentinvention (HCI) may be further processed by admixing with otheringredients, including other cereal based ingredients.

In such instances, it has been surprisingly discovered by the inventorsthat it results particularly advantageous to mix the HCI food productwith the remaining cereal based ingredients immediately before a heattreatment capable of inactivating the amylolytic enzymes (such as forexample step g) takes place. This approach is hereby referred to as “inline mixing” and provides the advantage of maintaining the low maltoselevels achieved via preparation of the HCI ingredient according to themethod of the invention, irrespective of the presence of still activeamylolytic enzymes in the resulting mixture.

To minimize the generation of sugars (maltose) in-between mixing andheat treatment, the length of the equipment, (for example pipe andstatic mixer) is set to have less than 30 seconds, for example 20seconds or less than 20 seconds, holding time for the lowest flow rates.

Further Steps

Yet further embodiments relate to the method according to the invention,further comprising the step g) additional heat treatment of the mixturewhich was obtained by high shear mixing according to steps a) to f).

The purpose of the heat treatment in step g) is to reducemicrobiological load of the product, as well as to inactivate enzymes,including the at least one further amylolytic enzyme from step b). Thus,the temperature and period of time of heat treatment of step g) will beselected in order to fulfil these two requirements and may be performedby any suitable means. It is considered to be within the skill of theperson with knowledge in the field to select the means as well asappropriate temperature and time. The heat treatment of step g) may befor example performed by bringing the temperature of the homogenizedmixture to a temperature in the range from 90 to 170 degrees Celsius,for a period of time from 2 seconds to 5 minutes.

In particular embodiments, the temperature in step g) is brought to atemperature in the range from 100 to 140 degrees C. for a period of timeof 4 seconds to 60 seconds.

In some particular embodiments, the heat treatment of step g) isperformed by direct steam injection.

The heat treatment of step g) may be performed after step e), such asdirectly after step e).

The method of the invention may further comprise one or more furthersteps wherein one or more yet further ingredients are added to mixture.These ingredients may be any ingredient suitable for the food productbeing manufactured. In particular, ingredients which are desired to beincluded in the final food product, but which may be negatively affectedby for example the heat and-or the high shear mixing of steps c) and d),may be advantageously added at a point after these said steps. Examplesof ingredients which may be negatively affected include heat sensitivenutrients such as heat-sensitive vitamins, and-or probiotics. Forexample, one or more yet further ingredients may be added after step e),for example after step e) and before step f), or for example immediatelyafter step e), or for example immediately after step e) and before stepf). In some embodiments the yet further one or more ingredients may beadded after step f), such as immediately after step f) and before anyfurther steps. The person skilled in the art will recognize therequirements of conventional ingredients, including heat-sensitivenutrients and can determine at which point these may be added.

In some embodiments, the method of the invention further comprises astep i) of cooling the mixture obtained by previous step. The coolingmay be effected by any suitable means, and may be for example to atemperature in the range from −20 degrees C. to 18 degrees C., such asfor example 0 to 10 degrees C., such as 0 to 5 degrees C.

In some embodiments, the method of the invention further comprises stepsof drying, for example roller drying, and milling in order to produce adried product which may be reconstituted before use.

In one embodiment, where optional ingredients are added in step b), theprocess comprises a drying step j). Drying is defined as the applicationof heat under controlled conditions, to remove the water present inliquid or semi-liquid foods and to yield solid products.

In one embodiment such step j) is a roller drying step.

The principle of roller drying process (or drum drying) is that a thinfilm of material is applied to the smooth surface of a continuouslyrotating, steam heated metal drum. The film of the drying material iscontinuously scraped off by a stationary knife located opposite to thepoint of application of the liquid or semi-liquid material.

The dryer consists of a single drum or a pair of drums with or withoutsatellite rollers.

Roller drying is a conventional drying technique in the art. The personskilled in the art will be able to select appropriate roller dryingtemperature and speed for the preparation of food products according tothe method of the invention.

In such embodiment, the product obtained may be a finished infant or allfamily cereal product to be consumed in the format of a porridge afterreconstitution as above described.

In another embodiment, where no optional ingredients are added in stepb), the mixture of step f) is subject to a heat treatment step g). Insuch embodiment, the product obtained may be an intermediate foodproduct as above defined (HCI).

The Product Obtainable by the Method

The invention relates in a second aspect to a food product obtainable bya method according to the invention. In one embodiment of this aspect,the invention relates to a product obtained by a method according to theinvention.

The food product according to the invention may be described ascomprising hydrolysed starch and reduced amounts of maltose. The termreduced amounts of maltose in this context means that amounts of maltosewhich are reduced as compared to amounts maltose produced byconventional starch hydrolysis processes, such as the one described inExample 1. In particular, the amount of maltose is reduced as comparedto starch hydrolysis methods which do not comprise the steps d) and e)of the present invented method.

In particular embodiments, the invention relates to a product accordingto the invention wherein the amount of maltose present is reduced by upto 100%, for example by 90%, for example by 80%, for example by 70% incomparison to conventional methods for example shown in Example 5 (76%).

In other embodiments, the invention relates to a product according tothe invention comprising from 1 to 19%, such as 1 to 15%, or 15 to 19%,or for example 5 to 10% of the amount of maltose present incorresponding product produced by conventional method. In furtherembodiments, the invention relates to a product comprising less than 6%w/w, such as 0.1% to 6%, 0.1 to 5% w/w, 0,1 to 4% w/w, 0,1 to 3% w/w,0,1 to 2.5% w/w or 0,05 to 2% w/w or 0,1 to 2% w/w maltose.

The product of the invention may be a liquid product, comprisinghydrolysed starch, or the liquid may be dried. The product may be aningredient, or a complete food.

In some embodiments of the method, the food product obtained is anintermediate. This means that the food product obtained is itself aningredient, and as such will be further worked up for example bycombining with further ingredients in order to achieve a final foodproduct.

Such an intermediate may also be referred to as an enzymaticallyhydrolysed carbohydrate ingredient (HCI).

A finished food product means a food product as sold to the consumer.Examples of final food products include infant formulas (e.g. in powderform or ready to drink), cereals, drinks, and the like.

It should be noted that embodiments and features described in thecontext of one of the aspects of the present invention also apply to theother aspects of the invention.

All patent and non-patent references cited in the present application,are hereby incorporated by reference in their entirety.

The invention will now be described in further details in the followingnon-limiting examples.

EXAMPLES Comparative Example 1: Conventional in-Line Hydrolysis Set Up

In this example of a conventional in-line hydrolysis process (where thehydrolysis is performed in the line of production of a finished foodproduct), a wheat flour, water and optionally other ingredients (e.g.sucrose, oils, etc.) are mixed in a preparation tank. The slurry is thenpumped into tubes. The alpha-amylase solution is injected in-line; thensteam is injected to reach the optimum temperature for the enzymeactivity (for example 65 deg C.). The alpha-amylase can also be added inthe initial liquid batch preparation tank. The slurry is then furtherprocessed at this optimum temperature for a residence time(corresponding to the incubation of step f), depending on the extent ofhydrolysis required (e.g. 2 to 10 minutes), before final heat treatmentfor hygienic reasons and enzymes inactivation (example: above 120° C.for 20 sec). The slurry (comprising around 50-55% w/w solids) is thensubject to a roller drying treatment (heat-treatment step, correspondingto step j) according to the process of the invention) to provide thefinished food product which may be then milled and packed for commercialuse. Roller drying treatment is performed in a bi-cylinder roller dryerat a temperature comprised between 150-190 deg C. (for example between185 and 190 deg C.) and at speed comprised between 0.5 and 5 rpm (forexample between 1 and 2 rpm).

Example 2: Method of the Invention in in-Line Hydrolysis

The method of the invention may also be incorporated as an in-linemethod of hydrolysis in method for producing a finished food product.

In one example of the method according to the invention, theconventional steps of “enzyme dosing—steam injection—incubation” asabove described in Example 1 are replaced by a Ring Layer Mixer.

A RLM with 10 litre capacity is used, with speed set between 400 and3000 rpm (for example between 1500 and 2000 rpm). The RLM has differentinlets, wherein the first inlet is used to introduce ingredients'mixture and second inlet for enzyme solution. Steam is injected via thethird inlet. The steam is used to bring the temperature of the flour andenzyme mix in the tank to a temperature of 40 degrees Celsius, asmeasured by a probe. The ingredient mixture is thus both heated andhomogenized. The resulting treated mixture is transported out of thering layer mixer to holding tubes. The treated mixture is incubated at40 degrees C. for a time longer than 1 minutes to allow the furtherhydrolysis by the enzymes.

The key characteristic of this high shear mixer is that it allows mixingwith steam and amylase.

FIG. 1 is a simplified process diagram for the in-line hydrolysis setupshowing equipment according to the process of the invention (Ring Layermixer—RLM) or conventional equipment (static mixer—ZL).

Comparative Example 3: Conventional in-Line Hydrolysis Set Up CarriedOut at Alternative Temperatures

With the purpose of comparing the sample with those obtained accordingto the process of the invention, roller dried cereals samples wereprepared as described in Example 1 but operating at a temperature of 40deg C. or 80 deg C.

Comparative Example 4: In-Line Hydrolysis Set Up Carried Out with RingLayer Mixer at Alternative Temperatures

With the purpose of comparing the sample with those obtained accordingto the process of the invention, roller dried cereals samples wereprepared as described in Example 2 but operating at temperature of 65 or80 deg C.

Example 5: Comparison of Maltose Content

Maltose reduction was measured in different set ups, with [set-updescribed in Comparative Examples 1 or 3)] and without ring layer mixer[set up described in Example 2].

Sugars profile (HPAEC method) were analyzed in roller-dried prototypes(obtained analogously as described above in Examples—and are reported inTable 1)

TABLE 1 Maltose values 80° C. 65° C. 40° C. ZL (Memil, 7.81% (Ex. 3)9.25% (Ex. 1) 4.79% (Ex. 3) conventional) RLM 2.37% (Ex. 4) 13.5% (Ex.4) 2.81% (Invention)

Table 1 shows that the amount of maltose produced in the set up where ahigh shear mixer (ring layer mixer) is used along with a temperature of40 deg C. is drastically reduced as compared to that of the conventionalset up at both 65 and 40 deg C.

Example 6: Maltose Content Generation with Ring Layer Mixer at DifferentOperating Conditions

Roller dried cereals samples were prepared as described in Example 2 butoperating at temperature of 45, 50, 55 deg C.

Results in terms of residual maltose content are reported in FIG. 2 .They show that reduced maltose contents with respect to conventionalhydrolysis conditions are obtained when a ring layer mixer equipment isused at a temperature lower than 55 deg C.

Example 7: Comparison of Sump Behavior

Sump behaviour in a bi-cylinder equipment was investigated for slurriesobtained for Examples 1 to 4 as above described before roller drying.The results obtained are reported in Table 2 below:

TABLE 2 Maltose in cereal powder Max (containing Line Bi-cylinder TS 75%flour) set-up T(° C.) Sump (%) (g/100 g) ZL 80 No formation 48 7.81(Memil) of Vapour Bubbles 65 Bubbly 50 9.25 40 Bubbly 50 4.79 RLM 80 Noformation 48 2.37 of Vapour Bubbles 65 Bubbly 50 13.05 40 Bubbly 50 2.81

As above discussed, obtaining a “bubbly” sump in a bi-cylinderroller-dryer is a key processing condition for a good film formation.The bubbling in the sump allows to mix the slurry inside the sump, andprevents the surface from drying up. If the sump does not bubble, then adrop of TS is usually required to avoid drying of the surface and issueswith roller-drying. A drop of TS is not desired as it leads to outputdecrease.

As it results from the results reported in Table 2, the hydrolysistemperature affects the sump “bubbliness”. At 80° C., the central sumpdoes not bubble anymore, and the total solids had to be decreased by 2%to enable a proper film formation under the operating conditions understudy. A drop of 3% of TS leads to an output decrease of 11%. At 65° C.and below, the sump exhibited bubbles, allowing to maintain the TotalSolids (TS) at 50% with a proper film formation and consequent advantagein the output.

As shown by the results reported in Examples 5, 6 and 7, the method ofthe invention not only allows preparation of food products comprisinghydrolized starch that have reduced maltose content, but also allows forgood processability of the slurry which translate into comparable outputto conventional hydrolysis conditions.

The invention claimed is:
 1. A method for producing a food ingredientcomprising hydrolysed starch, the method comprising: a) providing a dryplant preparation which comprises both starch and at least oneamylolytic enzyme, b) providing water and at least one furtheramylolytic enzyme, c) mixing the dry plant preparation of step a) andthe ingredients of step b) to form a mixture, d) adjusting thetemperature of the mixture of step c) to a temperature lower than 55°C., e) simultaneously to step d), subjecting the mixture of step c) tohigh shear mixing in a Ring Layer Mixer, f) incubating the mixture ofstep e) such that the desired degree of hydrolysis is achieved, andthereby obtaining the food ingredient comprising the hydrolysed starch.2. The method according to claim 1, wherein step d) is performed bydirect steam injection.
 3. The method according to claim 1, wherein thehigh shear mixing in step e) is such that the mixture is homogenizedwithin a time period of 1 second to 50 seconds.
 4. The method accordingto claim 1, wherein the dry plant preparation is selected from a flourof one or more grains; a flour made from one or more tubers; a flourmade from legumes; and combinations thereof.
 5. The method according toclaim 4, wherein the dry plant preparation comprises wheat flour.
 6. Themethod according to claim 1, wherein the at least one further amylolyticenzymes provided in step b) comprises amylase.
 7. The method accordingto claim 1, wherein the mixture of step c) has a total solids content inthe range of 20 to 60% w/w of the mixture.
 8. The method according toclaim 1, further comprising g) additional heat treatment of the mixturewhich was obtained by the high shear mixing according to steps a) to f).9. The method according to claim 1, wherein the food ingredientcomprises less than 6% w/w maltose of dry total weight of the foodingredient.
 10. The method according to claim 1, wherein the foodingredient comprises reduced levels of maltose as compared to thoseobtainable in a corresponding method, wherein the corresponding methodcomprises steps a)-d) and f) but not step e).
 11. The method accordingto claim 6, wherein the at least one further amylolytic enzyme providedin step b) comprises alpha-amylase, not endogenous to the dry plantpreparation.